Factory fabricated precompressed water and/or fire resistant expansion joint system transition

ABSTRACT

A fire and/or water resistant expansion joint system for installation into a building joint in vertical and horizontal configurations is designed such that it can be used for either an inside or outside corner. The system comprises a core having a fire retardant infused therein. A layer of an elastomer is disposed on the core and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system can be delivered to a job site in a pre-compressed state ready for installation into the building joint.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Continuation-in-Part Application of U.S. patentapplication Ser. No. 12/635,062, filed on Dec. 10, 2009, now U.S. Pat.No. 9,200,437, which claims the benefit of U.S. Provisional PatentApplication No. 61/121,590, filed on Dec. 11, 2008, the contents of eachof which are incorporated herein by reference in their entireties andthe benefits of each are fully claimed. This application also is aContinuation-in-Part Application of U.S. patent application Ser. No.13/729,500, filed on Dec. 28, 2012, which is a Continuation-in-PartApplication of U.S. patent application Ser. No. 12/622,574, filed onNov. 20, 2009, now U.S. Pat. No. 8,365,495 which includes reexaminationcertificate C1 issued Nov. 2, 2016, which claims the benefit of U.S.Provisional Patent Application No. 61/116,453, filed on Nov. 20, 2008,the contents of each of which are incorporated herein by reference intheir entireties and the benefits of each are fully claimed.

TECHNICAL FIELD

The present invention relates generally to joint systems for use inconcrete and other building systems and, more particularly, to expansionjoints for accommodating thermal and/or seismic movements in suchsystems.

BACKGROUND OF THE INVENTION

Concrete structures and other building systems often incorporate jointsthat accommodate movements due to thermal and/or seismic conditions.These joint systems may be positioned to extend through both interiorand exterior surfaces (e.g., walls, floors, and roofs) of a building orother structure.

In the case of an exterior joint in an exterior wall, roof, or floorexposed to external environmental conditions, the expansion joint systemshould also, to some degree, resist the effects of the externalenvironment conditions. As such, most external expansion joints systemsare designed to resist the effects of such conditions (particularlywater). In vertical joints, such conditions will likely be in the formof rain, snow, or ice that is driven by wind. In horizontal joints, theconditions will likely be in the form of rain, standing water, snow,ice, and in some circumstances all of these at the same time.Additionally, some horizontal systems may be subjected to pedestrianand/or vehicular traffic.

Many expansion joint products do not fully consider the irregular natureof building expansion joints. It is common for an expansion joint tohave several transition areas along the length thereof. These may bewalls, parapets, columns, or other obstructions. As such, the expansionjoint product, in some fashion or other, follows the joint as ittraverses these obstructions. In many products, this is a point ofweakness, as the homogeneous nature of the product is interrupted.Methods of handling these transitions include stitching, gluing, andwelding. In many situations, it is difficult or impossible toprefabricate these expansion joint transitions, as the exact details ofthe expansion joint and any transitions and/or dimensions may not beknown at the time of manufacturing.

In cases of this type, job site modifications are frequently made tofacilitate the function of the product with regard to the actualconditions encountered. Normally, one of two situations occurs. In thefirst, the product is modified to suit the actual expansion jointconditions. In the second, the manufacturer is made aware of issuespertaining to jobsite modifications, and requests to modify the productare presented to the manufacturer in an effort to better accommodate theexpansion joint conditions. In the first situation, there is a chancethat a person installing the product does not possess the adequate toolsor knowledge of the product to modify it in a way such that the productstill performs as designed or such that a transition that iscommensurate with the performance expected thereof can be effectivelycarried out. This can lead to a premature failure at the point ofmodification, which may result in subsequent damage to the property. Inthe second case, product is oftentimes returned to the manufacturer forrework, or it is simply scrapped and re-manufactured. Both return to themanufacturer and scrapping and re-manufacture are costly, and bothresult in delays with regard to the building construction, which can initself be extremely costly.

SUMMARY OF THE INVENTION

The present invention is directed to fire and/or water resistantexpansion joint systems for installation into building joints. In oneaspect, the present invention resides in a fire and water resistantsystem for use in vertical or horizontal configurations and is designedsuch that it can be used for either an inside or outside corner. Thesystem comprises a core having a fire retardant. A layer of an elastomeris disposed on the core and is tooled to define a profile to facilitatethe compression of the expansion joint system when installed betweencoplanar substrates. The system can be delivered to a job site in apre-compressed state ready for installation into the building joint.

In another aspect, the present invention resides in a fire and waterresistant vertical expansion joint system comprising a first section ofcore extending in a horizontal plane and a second section of coreextending in a vertical plane. An insert piece of core is locatedbetween the first and second sections, the insert piece being configuredto transition the first section from the horizontal plane to thevertical plane of the second section. The core is infused with a fireretardant. A layer of an elastomer is disposed on the core to impart asubstantially waterproof property thereto. The vertical expansion jointsystem is pre-compressed and is installable between horizontal coplanarsubstrates and vertical coplanar substrates. Although the verticalexpansion joint system is described as having an angle of transitionfrom horizontal to vertical, it should be understood that the transitionof the angles is not limited to right angles as the vertical expansionjoint system may be used to accommodate any angle.

In another aspect, the present invention resides in a fire and waterresistant expansion joint system, comprising a core; and a fireretardant infused into the core. The core infused with the fireretardant is configured to define a profile to facilitate thecompression of the expansion joint system when installed betweensubstantially coplanar substrates, and the expansion joint system isangled around a corner.

In any embodiment, the construction or assembly of the systems describedherein is generally carried out off-site, but elements of the system maybe trimmed to appropriate length on-site. By constructing or assemblingthe systems of the present invention in a factory setting, on-siteoperations typically carried out by an installer (who may not have theappropriate tools or training for complex installation procedures) canbe minimized. Accordingly, the opportunity for an installer to effect amodification such that the product does not perform as designed or suchthat a transition does not meet performance expectations is alsominimized.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vertical expansion joint system of thepresent invention.

FIG. 2 is an end view of the vertical expansion joint system taken alongline 2-2 of FIG. 1.

FIG. 3 is an end view of the vertical expansion joint system installedbetween two substrates.

FIG. 4 is a perspective view of an assembly of laminations beingprepared to produce the vertical expansion joint system of FIG. 1.

FIG. 5 is a perspective view of the assembly of laminations beingfurther prepared to produce the vertical expansion joint system of FIG.1.

FIG. 6 is a perspective view of four sections of the vertical expansionjoint system used in a building structure.

FIG. 7 is a perspective view of a horizontal expansion joint system ofthe present invention.

FIG. 8 is an end view of a vertical and/or horizontal expansion jointsystem installed between two substrates, depicting an elastomer on onesurface of the core and an intumescent material on another surface ofthe core.

FIG. 9 is an end view of a vertical and/or horizontal expansion jointsystem installed between two substrates, depicting alternative layeringon the core.

FIG. 10 is an end view of a vertical and/or horizontal expansion jointsystem installed between two substrates, depicting further layering onthe core.

FIG. 11 is an end view of a vertical and/or horizontal expansion jointsystem installed between two substrates, depicting a fire retardantlayer in the core and no coatings located on two outer surfaces of thecore.

FIG. 12 is an end view of a vertical and/or horizontal expansion jointsystem installed between two substrates, depicting a fire retardantmaterial in the core and layering on two outer surfaces of the core.

DETAILED DESCRIPTION

Embodiments of the present invention provide a resilient water resistantand/or fire resistant expansion joint system able to accommodatethermal, seismic, and other building movements while maintaining waterresistance and/or fire resistance characteristics. Embodiments ofpresent invention are especially suited for use in concrete buildingsand other concrete structures including, but not limited to, parkinggarages, stadiums, tunnels, bridges, waste water treatment systems andplants, potable water treatment systems and plants, and the like.

Referring now to FIGS. 1-3, embodiments of the present invention includean expansion joint system oriented in a vertical plane and configured totransition corners at right angles. This system is designated generallyby the reference number 10 and is hereinafter referred to as “verticalexpansion joint system 10.” It should be noted, however, that thevertical expansion joint system 10 is not limited to being configured atright angles, as the products and systems of the present invention canbe configured to accommodate any desired angle. The vertical expansionjoint system 10 comprises sections of a core 12′, e.g., open or closedcelled polyurethane foam 12 (hereinafter “foam 12” for ease of referencewhich is not meant to limit the core 12′ to a foam material, but merelyillustrate on exemplary material therefore) that may be infused with amaterial, such as a water-based acrylic chemistry, and/or other suitablematerial. As shown in Detail FIG. 2A, for example, the core 12′ can beinfused with a fire retardant material 60. Moreover, it should beunderstood, however, that the present invention is not limited to theuse of polyurethane foam, as other foams are within the scope of thepresent invention, and other non-foam materials also can be used for thecore 12′, as explained below.

As is shown in FIG. 2, the core 12′ and/or foam 12 can compriseindividual laminations 14 of material, e.g., foam, one or more of whichare infused with a suitable amount of material, e.g., such as theacrylic chemistry and/or fire retardant material 60. The individuallaminations 14 can extend substantially perpendicular to the directionin which the joint extends and be constructed by infusing at least one,e.g., an inner lamination with an amount of fire retardant 60. It shouldbe noted that the present invention is not so limited as other mannersof constructing the core 12′ and/or foam 12 are also possible. Forexample, the core 12′ and/or foam 12 of the present invention is notlimited to individual laminations 14 assembled to construct thelaminate, as the core 12′ and/or foam 12 may comprise a solid block ofnon-laminated foam or other material of fixed size depending upon thedesired joint size, laminates comprising laminations orientedhorizontally to adjacent laminations, e.g., parallel to the directionwhich the joint extends, or combinations of the foregoing.

Thus, foam 12 merely illustrates one suitable material for the core 12′.Accordingly, examples of materials for the core 12′ include, but are notlimited to, foam, e.g., polyurethane foam and/or polyether foam, and canbe of an open cell or dense, closed cell construction. Further examplesof materials for the core 12′ include paper based products, cardboard,metal, plastics, thermoplastics, dense closed cell foam includingpolyurethane and polyether open or closed cell foam, cross-linked foam,neoprene foam rubber, urethane, ethyl vinyl acetate (EVA), silicone, acore chemistry (e.g., foam chemistry) which inherently impartshydrophobic and/or fire resistant characteristics to the core; and/orcomposites. Combinations of any of the foregoing materials or othersuitable material also can be employed. It is further noted that whilefoam 12 is primarily referred to herein as a material for the core 12′,the descriptions for foam 12 also can apply to other materials for thecore 12′, as explained above.

The core 12′ can be infused with a suitable material including, but notlimited to, an acrylic, such as a water-based acrylic chemistry, a wax,a fire retardant material, ultraviolet (UV) stabilizers, and/orpolymeric materials, combinations thereof, and so forth. A particularlysuitable embodiment is a core 12′ comprising an open celled foam infusedwith a water-based acrylic chemistry and/or a fire retardant material.

The amount of fire retardant material 60 that can be infused into thecore 12′, including the open celled foam embodiment, is between 3.5:1and 4:1 by weight in ratio with the un-infused foam/core itself,according to embodiments. The resultant uncompressed foam/core, whethercomprising a solid block or laminates, has a density of about 130 kg/m³to about 150 kg/m³ and preferably about 140 kg/m³. Other suitabledensities for the resultant core 12′ include between about 50 kg/m³ andabout 250 kg/m³, e.g., between about 100 kg/m³ and about 180 kg/m³, andwhich are capable of providing desired water resistance and/orwaterproofing characteristics to the structure. One type of fireretardant material 60 that may be used is water-based aluminumtri-hydrate (also known as aluminum tri-hydroxide (ATH)). The presentinvention is not limited in this regard, however, as other fireretardant materials may be used. Such materials include, but are notlimited to, metal oxides and other metal hydroxides, aluminum oxides,antimony oxides and hydroxides, iron compounds such as ferrocene,molybdenum trioxide, nitrogen-based compounds, phosphorus basedcompounds, halogen based compounds, halogens, e.g., fluorine, chlorine,bromine, iodine, astatine, combinations of any of the foregoingmaterials, and other compounds capable of suppressing combustion andsmoke formation. Also as is shown in FIG. 3, the vertical expansionjoint system 10 is positionable between opposing substrates 18 (whichmay comprise concrete, glass, wood, stone, metal, or the like) toaccommodate the movement thereof. In particular, opposing verticalsurfaces of the core 12′ and/or foam 12 can be retained between theedges of the substrates 18. The compression of the core 12′ and/or foam12 during the installation thereof between the substrates 18 enables thevertical expansion system 10 to be held in place.

In any embodiment, when individual laminations 14 are used, severallaminations, the number depending on the expansion joint size (e.g., thewidth, which depends on the distance between opposing substrates 18 intowhich the vertical expansion system 10 is to be installed), can becompiled and then compressed and held at such compression in a fixture.The fixture, referred to as a coating fixture, is at a width slightlygreater than that which the expansion joint will experience at thegreatest possible movement thereof. Similarly, a core 12′ comprisinglaminations of non-foam material or comprising a solid block of desiredmaterial may be compiled and then compressed and held at suchcompression in a suitable fixture.

In the fixture, the assembled infused laminations 14 or core 12′ arecoated with a coating, such as a waterproof elastomer 20 at one surface,according to embodiments. The elastomer 20 may comprise, for example, atleast one polysulfide, silicone, acrylic, polyurethane, poly-epoxide,silyl-terminated polyether, combinations and formulations thereof, andthe like, with or without other elastomeric components or similarsuitable elastomeric coating or liquid sealant materials, or a mixture,blend, or other formulation of one or more the foregoing. One preferredelastomer 20 for coating core 12′, e.g., for coating laminations 14 fora horizontal deck application where vehicular traffic is expected isPECORA 301 (available from Pecora Corporation, Harleysville, Pa.) or DOW888 (available from Dow Corning Corporation, Midland, Mich.), both ofwhich are traffic grade rated silicone pavement sealants. For verticalwall applications, a preferred elastomer 20 for coating, e.g., thelaminations 14 is DOW 790 (available from Dow Corning Corporation,Midland, Mich.), DOW 795 (also available from Dow Corning Corporation),or PECORA 890 (available from Pecora Corporation, Harleysville, Pa.). Aprimer may be used depending on the nature of the adhesivecharacteristics of the elastomer 20. For example, a primer may beapplied to the outer surfaces of the laminations 14 of foam 12 and/orcore 12′ prior to coating with the elastomer 20. Applying such a primermay facilitate the adhesion of the elastomer 20 to the foam 12 and/orcore 12′.

During or after application of the elastomer 20 to the laminations 14and/or core 12′, the elastomer is tooled or otherwise configured tocreate a “bellows,” “bullet,” or other suitable profile such that thevertical expansion joint system 10 can be compressed in a uniform andaesthetic fashion while being maintained in a virtually tensionlessenvironment.

The elastomer 20 is then allowed to cure while being maintained in thisposition, securely bonding it to the infused foam lamination 14 and/orcore 12′.

Referring now to FIGS. 4 and 5, when the elastomer 20 has cured inplace, the infused foam lamination 14 and/or core 12′ is cut in alocation at which a bend in the vertical expansion system 10 is desiredto accommodate a corner. The cut, which is designated by the referencenumber 24 and as shown in FIG. 4, is made from the outside of thedesired location of the bend to the inside of the desired location ofthe bend using a saw or any other suitable device. The cut 24 is stoppedsuch that a distance d is defined from the termination of the cut to thepreviously applied coating of the elastomer 20 on the inside of thedesired location of the bend (e.g., approximately one half inch from thepreviously applied coating of elastomer 20 on the inside of the bend).Referring now to FIG. 5, the lamination 14 is then bent to anappropriate angle A, thereby forming a gap G at the outside of the bend.Although a gap of 90 degrees is shown in FIG. 5, the present inventionis not limited in this regard as other angles are possible.

Still referring to FIG. 5, a piece of core 12′ and/or infused foamlamination constructed in a manner similar to that described above isinserted into the gap G as an insert piece 30 and held in place by theapplication of a similar coating of elastomer 20 as described above. Inthe alternative, the insert piece 30 may be held in place using asuitable adhesive. Accordingly, the angle A around the corner is madecontinuous via the insertion of the insert piece 30 located between asection of the open celled foam extending in the horizontal plane and asection of the open celled foam extending in the vertical plane. Oncethe gap has been filled and the insert piece 30 is securely in position,the entire vertical expansion system 10 including the insert piece 30 isinserted into a similar coating fixture with the previously appliedelastomer 20 coated side facing down and the uncoated side facingupwards. The uncoated side is now coated with the same (or different)elastomer 20 as was used on the opposite face. Again, the elastomer 20is then allowed to cure in position. Furthermore, the insert piece 30inserted into the gap is not limited to being a lamination 14, as solidblocks or the like may be used.

After both sides have cured, the vertical expansion system 10 as thefinal uninstalled product is removed from the coating fixture andpackaged for shipment. In the packaging operation the vertical expansionsystem 10 is compressed using a hydraulic or mechanical press (or thelike) to a size below the nominal size of the expansion joint at the jobsite. The vertical expansion system 10 is held at this size using a heatshrinkable poly film. The present invention is not limited in thisregard, however, as other devices (ties or the like) may be used to holdthe vertical expansion system 10 to the desired size.

Referring now to FIG. 6, portions of the vertical expansion system 10positioned to articulate right angle bends are shown as they would bepositioned in a concrete expansion joint located in a tunnel, archway,or similar structure. Each portion defines a foam laminate that ispositioned in a corner of the joint. As is shown, the vertical expansionjoint system 10 is installed between horizontal coplanar substrates 18 aand vertical coplanar substrates 18 b.

Referring now to FIG. 7, an alternate embodiment of the invention isshown. In this embodiment, the infused core 12′ and/or foam, theelastomer coating on the top surface, and the elastomer coating on thebottom surface are similar to the above described embodiments. However,in FIG. 7, the expansion joint system designated generally by thereference number 110 is oriented in the horizontal plane rather thanvertical plane and is hereinafter referred to as “horizontal expansionsystem 110.” As with the vertical expansion system 10 described above,the horizontal expansion system 110 may be configured to transitionright angles. The horizontal expansion system 110 is not limited tobeing configured to transition right angles, however, as it can beconfigured to accommodate any desired angle.

In the horizontal expansion system 110, the infused core 12′ and/or foamlamination 14 is constructed in a similar fashion to that of thevertical expansion system 10, namely, by constructing a core 12′ and/orfoam 112 assembled from individual laminations 114 of suitable material,such as a foam material, one or more of which is infused with, e.g., anacrylic chemistry and/or a fire retardant material 60. Although thehorizontal expansion system 110 is described as being fabricated fromindividual laminations 114, the present invention is not so limited, andother manners of constructing the core 12′ and/or foam 112 are possible(e.g., solid blocks of material, e.g., foam material, as describedabove).

In fabricating the horizontal expansion system 110, two pieces of thecore 12′ and/or foam 112 are mitered at appropriate angles B (45 degreesis shown in FIG. 7, although other angles are possible). An elastomer,or other suitable adhesive, is applied to the mitered faces of theinfused foam laminations. The individual laminations are then pushedtogether and held in place in a coating fixture at a width slightlygreater than the largest joint movement anticipated. At this width thetop is coated with an elastomer 20 and cured, according to embodiments.Following this, the core 12′ and/or foam 112 is inverted and then theopposite side is likewise coated.

After both coatings of elastomer 20 have cured, the horizontal expansionsystem 110 is removed from the coating fixture and packaged forshipment. In the packaging operation, the horizontal expansion system110 is compressed using a hydraulic or mechanical press (or the like) toa size below the nominal size of the expansion joint at the job site.The product is held at this size using a heat shrinkable poly film (orany other suitable device).

In a horizontal expansion system, e.g., system 110, the installationthereof can be accomplished by adhering the core 12′ and/or foam 112 toa substrate (e.g., concrete, glass, wood, stone, metal, or the like)using an adhesive such as epoxy. The epoxy or other adhesive is appliedto the faces of the horizontal expansion system 110 prior to removingthe horizontal expansion system from the packaging restraints thereof.Once the packaging has been removed, the horizontal expansion system 110will begin to expand, and the horizontal expansion system is insertedinto the joint in the desired orientation. Once the horizontal expansionsystem 110 has expanded to suit the expansion joint, it will becomelocked in by the combination of the core 12′ and/or foam back pressureand the adhesive.

In any system of the present invention, but particularly with regard tothe vertical expansion system 10, an adhesive may be pre-applied to thecore 12′ and/or foam lamination. In this case, for installation, thecore 12′ and/or foam lamination is removed from the packaging and simplyinserted into the expansion joint where it is allowed to expand to meetthe concrete (or other) substrate. Once this is done, the adhesive incombination with the back pressure of the core 12′ and/or foam will holdthe foam in position.

The vertical expansion system 10 is generally used where there arevertical plane transitions in the expansion joint. For example, verticalplane transitions can occur where an expansion joint traverses a parkingdeck and then meets a sidewalk followed by a parapet wall. The expansionjoint cuts through both the sidewalk and the parapet wall. In situationsof this type, the vertical expansion system 10 also transitions from theparking deck (horizontally) to the curb (vertical), to the sidewalk(horizontal), and then from the sidewalk to the parapet (vertical) andin most cases across the parapet wall (horizontal) and down the otherside of the parapet wall (vertical). Prior to the present invention,this would result in an installer having to fabricate most or all ofthese transitions on site using straight pieces. This process wasdifficult, time consuming, and error prone, and often resulted in wasteand sometimes in sub-standard transitions.

In one example of installing the vertical expansion system 10 in astructure having a sidewalk and a parapet, the installer uses severalindividual sections, each section being configured to transition anangle. The installer uses the straight run of expansion joint product,stopping within about 12 inches of the transition, then installs onesection of the vertical expansion system 10 with legs measuring about 12inches by about 6 inches. If desired, the installer trims the legs ofthe vertical expansion system 10 to accommodate the straight run and theheight of the sidewalk. Standard product is then installed across thesidewalk, stopping short of the transition to the parapet wall. Hereanother section of the vertical expansion system 10 is installed, whichwill take the product up the wall. Two further sections of the verticalexpansion system 10 are used at the top inside and top outside cornersof the parapet wall. The sections of the vertical expansion system 10are adhered to each other and to the straight run expansion jointproduct in a similar fashion as the straight run product is adhered toitself. In this manner, the vertical expansion system 10 can be easilyinstalled if the installer has been trained to install the standardstraight run product. It should be noted, however, that the presentinvention is not limited to the installation of product in anyparticular sequence as the pieces can be installed in any suitableand/or desired order.

In one example of installing the horizontal expansion system 110, thesystem is installed where there are horizontal plane transitions in theexpansion joint. This can happen when the expansion joint encountersobstructions such as supporting columns or walls. The horizontalexpansion system 110 is configured to accommodate such obstructions.Prior to the present invention, the installer would have had to createfield transitions to follow the expansion joint.

To extend a horizontal expansion system, e.g., system 110, around atypical support column, the installer uses four sections of thehorizontal expansion system. A straight run of expansion joint productis installed and stopped approximately 12 inches short of the horizontaltransition. The first section of the horizontal expansion system 110 isthen installed to change directions, trimming as desired for thespecific situation. Three additional sections of horizontal expansionsystem 110 are then joined, inserting straight run pieces as desired,such that the horizontal expansion system 110 extends around the columncontinues the straight run expansion joint on the opposite side. As withthe vertical expansion system 10, the sections may be installed in anysequence that is desired.

The present invention is not limited to products configured at rightangles, as any desired angle can be used for either a horizontal orvertical configuration. Also, the present invention is not limited tofoam or laminates, as solid blocks of foam or other desired material andthe like may alternatively or additionally be used.

Moreover, while a core 12′ coated with an elastomer 20 on one or both ofits outer surfaces has been primarily described above, according toembodiments, the present invention is not limited in this regard. Thus,the vertical and horizontal expansion joint systems described herein arenot limited in this regard. For example, as shown in FIG. 8, the surfaceof the infused foam laminate and/or core 12′ opposite the surface coatedwith elastomer 20 is coated with an intumescent material 16, accordingto further embodiments. One type of intumescent material 16 may be acaulk having fire barrier properties. A caulk is generally a silicone,polyurethane, polysulfide, sylil-terminated-polyether, or polyurethaneand acrylic sealing agent in latex or elastomeric base. Fire barrierproperties are generally imparted to a caulk via the incorporation ofone or more fire retardant agents. One preferred intumescent material 16is 3M CP25WB+, which is a fire barrier caulk available from 3M of St.Paul, Minn. Like the elastomer 20, the intumescent material 16 is tooledor otherwise configured to create a “bellows” or other suitable profileto facilitate the compression of the foam lamination and/or core 12′.After tooling or otherwise configuring to have, e.g., the bellows-typeof profile, both the coating of the elastomer 20 and the intumescentmaterial 16 are cured in place on the foam 12 and/or core 12′ while theinfused foam lamination and/or core 12′ is held at the prescribedcompressed width. After the elastomer 20 and the intumescent material 16have been cured, the entire composite is removed from the fixture,optionally compressed to less than the nominal size of the material andpackaged for shipment to the job site. This embodiment is particularlysuited to horizontal parking deck applications where waterproofing isdesired on the top side and fire resistance is desired from beneath, asin the event of a vehicle fire on the parking deck below.

A sealant band and/or corner bead 19 of the elastomer 20 can be appliedon the side(s) of the interface between the foam laminate (and/or core12′) and the substrate 18 to create a water tight seal.

Referring now to FIG. 9, an alternate expansion joint system of thepresent invention illustrates the core 12′ having a first elastomer 14coated on one surface and the intumescent material 16 coated on anopposing surface. A second elastomer 15 is coated on the intumescentmaterial 16 and serves the function of waterproofing. In this manner,the system is water resistant in both directions and fire resistant inone direction. The system of FIG. 9 is used in applications that aresimilar to the applications in which the other afore-referenced systemsare used, but may also be used where water is present on the undersideof the expansion joint. Additionally, it would be suitable for verticalexpansion joints where waterproofing or water resistance is desirable inboth directions while fire resistance is desired in only one direction.The second elastomer 15 may also serve to aesthetically integrate thesystem with surrounding substrate material.

Sealant bands and/or corner beads 19 of the first elastomer 20 can beapplied to the sides as with the embodiments described above. Sealantbands and/or corner beads 24 can be applied on top of the secondelastomer 15, thereby creating a water tight seal between the substrateand the intumescent material 16.

Referring now to FIG. 10, in this embodiment, the foam 12 and/or core12′ is similar to or the same as the above-described foam and/or core12′, but both exposed surfaces are coated first with the intumescentmaterial 16 to define a first coating of the intumescent material and asecond coating of the intumescent material 16. The first coating of theintumescent material 16 is coated with a first elastomer material 32,and the second coating of the intumescent material 16 is coated with asecond elastomer material 34. This system can be used in the sameenvironments as the above-described systems with the added benefit thatit is both waterproof or at least water resistant and fire resistant inboth directions through the joint. This makes it especially suitable forvertical joints in either interior or exterior applications.

Sealant bands and/or corner beads 38 of the elastomer can be applied ina similar fashion as described above and on both sides of the foam 12and/or core 12′. This creates a water tight elastomer layer on bothsides of the foam 12 and/or core 12′.

Referring now to FIG. 11, shown therein is another system, according toembodiments. In FIG. 11, the core 12′ is infused with a fire retardantmaterial, as described above. As an example, the fire retardant materialcan form a “sandwich type” construction wherein the fire retardantmaterial forms a layer 15′, as shown in FIG. 11, between the material ofcore 12′. Thus, the layer 15′ comprising a fire retardant can be locatedwithin the body of the core 12′ as, e.g., an inner layer, or laminationinfused with a higher ratio or density of fire retardant than the core12′. It is noted that the term “infused with” as used throughout thedescriptions herein is meant to be broadly interpreted to refer to“includes” or “including.” Thus, for example, “a core infused with afire retardant” covers a “core including a fire retardant” in any formand amount, such as a layer, and so forth. Accordingly, as used herein,the term “infused with” would also include, but not be limited to, moreparticular embodiments such as “permeated” or “filled with” and soforth.

Moreover, it is noted that layer 15′ is not limited to the exactlocation within the core 12′ shown in FIG. 11 as the layer 15′ may beincluded at various depths in the core 12′ as desired. Moreover, it isfurther noted that the layer 15′ may extend in any direction. Forexample, layer 15′ may be oriented parallel to the direction in whichthe joint extends, perpendicular to the direction in which the jointextends or combinations of the foregoing. Layer 15′ can function as afire resistant barrier layer within the body of the core 12′.Accordingly, layer 15′ can comprise any suitable material providing,e.g., fire barrier properties. No coatings are shown on the outersurfaces of core 12′ of FIG. 11.

Accordingly, by tailoring the density as described above to achieve thedesired water resistance and/or water proofing properties of thestructure, combined with the infused fire retardant in layer 15′, orinfused within the core 12′ in any other desired form including anon-layered form, additional layers, e.g. an additional water and/orfire resistant layer on either or both outer surfaces of the core 12′,are not be necessary to achieve a dual functioning water and fireresistant system, according to embodiments.

It is noted, however, that additional layers could be employed ifdesired in the embodiment of FIG. 11, as well as in the otherembodiments disclosed herein, and in any suitable combination and order.For example, the layering described above with respect to FIGS. 1-10could be employed in the embodiment of FIG. 11 and/or FIG. 12 describedbelow.

As a further example, FIG. 12 illustrates therein an expansion jointsystem comprising the layer 15′ comprising a fire retardant within thebody of the core 12′ as described above with respect to FIG. 11, andalso comprising an additional coating 17 on a surface of the core 12′.Coating 17 can comprise any suitable coating, such as the elastomer 20described above, a fire barrier material including an intumescentmaterial 16 described above or other suitable fire barrier material,e.g., a sealant, a fabric, a blanket, a foil, a tape, e.g., anintumescent tape, a mesh, a glass, e.g., fiberglass; and combinationsthereof.

Moreover, embodiments include various combinations of layering and fireretardant infusion (in layer and non-layer form) to achieve, e.g., thedual functioning water and fire resistant expansion joint systemsdescribed herein, according to embodiments. For example, FIG. 12illustrates coating 17 on one surface of the core 12′ and a dual coating18 on the opposite surface of the core 12′. The dual coating 18 cancomprise, e.g., an inner layer of elastomer 20, as described above, withan outer layer of a fire barrier material including, e.g., anintumescent material. Similarly, the layers of the dual coating 18 canbe reversed to comprise an inner layer of fire barrier material and anouter layer of elastomer 20.

Alternatively, only one layer may be present on either surface of core12′, such as one layer of a fire barrier material, e.g., sealant, on asurface of the core 12′, which is infused with a fire retardant materialin layer 15′ or infused in a non-layer form. Still further, othercombinations of suitable layering include, e.g., dual coating 18 on bothsurfaces of the core 12′ and in any combination of inner and outerlayers, as described above.

It is additionally noted that the embodiments shown in, e.g., FIGS. 8-12can be similarly constructed and installed, as described above withrespect to, e.g., the embodiments of FIGS. 1-7, modified as appropriatefor inclusion/deletion of various layering, and so forth. Thus, forexample, as described above, while a “bellows” construction isillustrated by the figures, the embodiments described herein are notlimited to such a profile as other suitable profiles may be employed,such as straight, curved, and so forth.

Accordingly, as further evident from the foregoing, embodiments of thedual functioning fire and water resistant expansion joint systems cancomprise various ordering and layering of materials on the outersurfaces of the core 12′. Similarly, a fire retardant material can beinfused into the core 12′ in various forms, to create, e.g., a layered“sandwich type” construction with use of, e.g., layer 15′.

In the embodiments described herein, the infused foam laminate and/orcore 12′ may be constructed in a manner which insures that substantiallythe same density of fire retardant 60 is present in the productregardless of the final size of the product, according to embodiments.The starting density of the infused foam/core is approximately 140kg/m³, according to embodiments. Other suitable densities includebetween about 80 kg/m³ and about 180 kg/m³. After compression, theinfused foam/core density is in the range of about 160-800 kg/m³,according to embodiments. After installation the laminate and/or core12′ will typically cycle between densities of approximately 750 kg/m³ atthe smallest size of the expansion joint to approximately 360-450 kg/m³,e.g., approximately 400-450 kg/m³ (or less) at the maximum size of thejoint. A density of 400-450 kg/m³ was determined throughexperimentation, as a reasonable value which still affords adequate fireretardant capacity, such that the resultant composite can pass the UL2079 test program. The present invention is not limited to cycling inthe foregoing ranges, however, and the foam/core may attain densitiesoutside of the herein-described ranges.

It is further noted that various embodiments, including constructions,layering and so forth described herein can be combined in any order toresult in, e.g., a dual functioning water and fire resistant expansionjoint system. Thus, embodiments described herein are not limited to thespecific construction of the figures, as the various materials, layeringand so forth described herein can be combined in any desired combinationand order.

Although this invention has been shown and described with respect to thedetailed embodiments thereof, it will be understood by those of skill inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of theinvention. In addition, modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodimentsdisclosed in the above detailed description, but that the invention willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. A fire and water resistant expansion jointsystem, comprising: a core; a fire retardant infused into the core; anda water resistant layer disposed on the core; wherein the layer istooled to define a profile to facilitate compression of the expansionjoint system when installed between substrates, wherein the core infusedwith the fire retardant compressed has as a density of about 160 kg/m³to about 800 kg/m³; and wherein the expansion joint system is angledaround a corner, and the fire and water resistant expansion joint systemand the core infused with the fire retardant are configured to passtesting mandated by UL
 2079. 2. The expansion joint system of claim 1,wherein the core comprises a plurality of individual laminationsassembled to construct a laminate, one or more of the laminations beinginfused with at least one of the fire retardant and a water-basedacrylic chemistry.
 3. The expansion joint system of claim 1, whereinvertically oriented surfaces of the core are retained between edges ofthe coplanar substrates.
 4. The expansion joint system of claim 1,wherein the core comprises foam.
 5. The expansion joint system of claim4, wherein the water resistant layer disposed on the foam is selectedfrom the group consisting of polysulfides, acrylics, polyurethanes,poly-epoxides, silyl-terminated polyethers, and combinations of one ormore of the foregoing.
 6. The expansion joint system of claim 4, whereinthe core comprises a block of foam.
 7. The expansion joint system ofclaim 1, wherein the water resistant layer disposed on the corecomprises a silicone.
 8. The expansion joint system of claim 1, whereinthe water resistant layer is tooled to define at least one of a bellowsprofile and a bullet profile.
 9. The expansion joint system of claim 1,wherein the expansion joint system is angled around the corner to extendfrom a horizontal plane to a vertical plane.
 10. The expansion jointsystem of claim 9, wherein the angle around the corner is madecontinuous via the insertion of an insert piece located between asection of the core extending in the horizontal plane and a section ofthe core extending in the vertical plane.
 11. The expansion joint systemof claim 1, wherein the expansion joint system is angled around thecorner and extends in a horizontal plane.
 12. The expansion joint systemof claim 11, wherein the angle around the corner comprises a miter jointbetween two sections of the core extending in the horizontal plane. 13.The expansion joint system of claim 12, wherein the two sections of coreextending in the horizontal plane are adhesively joined.
 14. Theexpansion joint system of claim 1, wherein the ratio of the fireretardant infused into the core is in a range of about 3.5:1 to about4:1 by weight.
 15. The expansion joint system of claim 1, wherein alayer comprising the fire retardant is sandwiched between the materialof the core.
 16. The expansion joint system of claim 1, wherein the fireretardant infused into the core is selected from the group consisting ofwater-based alumina tri-hydrate, metal oxides, metal hydroxides,aluminum oxides, antimony oxides and hydroxides, iron compounds,ferrocene, molybdenum trioxide, nitrogen-based compounds, phosphorusbased compounds, halogen based compounds, halogens, and combinations ofthe foregoing materials.
 17. The expansion joint system of claim 1,wherein the core uncompressed has a density of about 100 kg/m³ to about180 kg/m³.
 18. The expansion joint system of claim 1, further comprisinga second layer disposed on the water resistant layer, wherein the secondlayer is selected from the group consisting of another water resistantlayer, a fire barrier layer and combinations thereof.
 19. The expansionjoint system of claim 1, wherein a first coating is located on a surfaceof the core, and a second coating is located on a surface of the coreopposing the first coating, wherein the first coating is thesubstantially the same as or different than the second coating.
 20. Theexpansion joint system of claim 1, wherein the fire and water resistantexpansion joint system is capable of withstanding exposure to atemperature of about 930° C. at about one hour.
 21. The expansion jointsystem of claim 1, wherein the fire and water resistant expansion jointsystem is capable of withstanding exposure to a temperature of about1010° C. at about two hours.
 22. The expansion joint system of claim 1,wherein the fire and water resistant expansion joint system is capableof withstanding exposure to a temperature of about 1260° C. at abouteight hours.
 23. The expansion joint system of claim 22, wherein theratio of the fire retardant material infused into the core is in a rangeof about 3.5:1 to about 4:1 by weight.
 24. The expansion joint system ofclaim 1, wherein the expansion joint system is a tunnel expansion jointsystem.
 25. The expansion joint system of claim 1, wherein the coreinfused with the fire retardant uncompressed has as a density of about50 kg/m³ to about 250 kg/m³.
 26. A fire and water resistant verticalexpansion joint system, comprising: a first section of core extending ina horizontal plane; a second section of core extending in a verticalplane; an insert piece of core located between the first section of coreextending in the horizontal plane and the second section of coreextending in the vertical plane, the insert piece being configured totransition the first section of the core from the horizontal plane tothe vertical plane of the second section of the core; and a waterresistant layer disposed on the core, the water resistant layerimparting a substantially waterproof property to the core, wherein thewater resistant layer is a continuous layer of the water resistant layerfrom the vertical plane to the horizontal plane and the water resistantlayer is a continuous layer of the water resistant layer over the insertpiece, and the insert piece is held in place by the continuous layer ofthe water resistant layer, and the expansion joint system is configuredto accommodate at least one of thermal and seismic movement in thesystem; wherein the core is infused with a fire retardant; wherein thefire and water resistant vertical expansion joint system is installablebetween horizontal substrates and vertical substrates, wherein the coreinfused with the fire retardant compressed has as a density of about 160kg/m³ to about 800 kg/m³; and wherein the fire and water resistantvertical expansion joint system and the core infused with the fireretardant are configured to pass movement cycling and fire endurancetesting mandated by UL
 2079. 27. The vertical expansion joint system ofclaim 26, wherein the core comprises a plurality of individuallaminations assembled to construct a laminate.
 28. The verticalexpansion joint system of claim 27, wherein the core comprises opencelled polyurethane foam.
 29. The vertical expansion joint system ofclaim 26, further comprising an acrylic infused in the core.
 30. Thevertical expansion joint system of claim 26, wherein the ratio of thefire retardant infused into the core is in a range of about 3.5:1 toabout 4:1 by weight.
 31. The vertical expansion joint system of claim26, wherein a layer comprising the fire retardant is sandwiched betweenthe material of the core.
 32. The vertical expansion joint system ofclaim 26, wherein the fire and water resistant vertical expansion jointsystem is capable of withstanding exposure to a temperature of about1010° C. at about two hours.
 33. The vertical expansion joint system ofclaim 26, wherein the fire and water resistant vertical expansion jointsystem is capable of withstanding exposure to a temperature of about1260° C. at about eight hours.
 34. The vertical expansion joint systemof claim 33, wherein the ratio of the fire retardant material infusedinto the core is in a range of about 3.5:1 to about 4:1 by weight. 35.The expansion joint system of claim 26, wherein the core infused withthe fire retardant uncompressed has as a density of about 50 kg/m³ toabout 250 kg/m³.
 36. A fire and water resistant expansion joint system,comprising: a core; a fire retardant infused into the core; wherein thecore infused with the fire retardant is configured to define a profileto facilitate the compression of the expansion joint system wheninstalled between substrates, wherein the core infused with the fireretardant compressed has as a density of about 160 kg/m³ to about 800kg/m³; and wherein the expansion joint system is angled around a corner,and the fire and water resistant expansion joint system and the coreinfused with the fire retardant are configured to pass testing mandatedby UL
 2079. 37. The expansion joint system of claim 36, wherein the corecomprises a first outer surface and a second outer surface, and nocoatings are located on either the first outer surface or the secondouter surface.
 38. The fire and water resistant expansion joint systemof claim 36, wherein the fire and water resistant expansion joint systemis capable of withstanding exposure to a temperature of about 1260° C.at about eight hours, and the ratio of the fire retardant materialinfused into the core is in a range of about 3.5:1 to about 4:1 byweight.
 39. The expansion joint system of claim 36, wherein theexpansion joint system is a tunnel expansion system.
 40. The expansionjoint system of claim 36, wherein the core infused with the fireretardant uncompressed has as a density of about 50 kg/m³ to about 250kg/m³.